CN112528535A - Mortise broaching process simulation analysis method based on heat-force-flow multi-field coupling - Google Patents
Mortise broaching process simulation analysis method based on heat-force-flow multi-field coupling Download PDFInfo
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Abstract
The invention discloses a mortise broaching process simulation analysis method based on thermal-force-flow multi-field coupling, which comprises the following steps of: establishing a broaching heat-force model according to the sizes of the cutter and the workpiece, the relevant parameters of the material, the relevant cutting parameters and the heat conduction characteristics and carrying out simulation; establishing a broaching heat-flow model according to cooling related parameters of a cutter, a workpiece and cooling liquid and performing analog simulation; and coupling the simulation results of the broaching heat-force model and the broaching heat-flow model to obtain a broaching heat-force-flow multi-field coupling model, and simulating the cooling effect of cooling liquid on a workpiece, a cutter and chips in the broaching process. According to the invention, thermal-force and thermal-flow simulation analysis models in the broaching process are established, a data transmission platform between the models is established, coupling simulation analysis between three fields of broaching thermal-force-flow is realized, the flow speed, the temperature and the impact pressure of cooling liquid are fully considered, and the simulation precision is greatly improved.
Description
Technical Field
The invention relates to the field of broaching process simulation, in particular to a mortise broaching process simulation analysis method based on thermal-force-flow multi-field coupling.
Background
The tenon tooth-mortise assembly is a common assembly method in a turbine engine, has the characteristic of high dimensional accuracy, and is widely applied to the field of aeronautical machinery, such as the accurate positioning of blade parts and the like. The wheel disc is one of the core components, and the wheel disc bears high-temperature and high-pressure alternating loads during working. The blade is connected with the wheel disc mortise through the blade root tenon tooth, and the service life of the system is directly determined by the reliability of the tenon joint structure (tenon tooth-mortise). The positioning accuracy of the blade tenon tooth-mortise structure directly influences the assembly precision and the service performance of the blade, is determined by the size precision of the mortise and the tenon tooth, and according to statistics, about 20% of system faults are caused by the failure of the wheel disc mortise tooth-blade tenon tooth connecting structure. Therefore, the machining of the wheel disc mortise is one of the key quality control procedures for manufacturing the turbine engine, the machining precision and the machining surface integrity directly determine the matching firmness, the force transmission characteristic, the fatigue fracture resistance, the creep resistance, the corrosion resistance and the like of the wheel disc mortise, and finally determine the working reliability and the service performance of the system.
In the prior art, commercial software such as ABAQUS, DEFLROM, ADVANTEDGE and the like can be adopted to simulate the broaching physical process to assist in carrying out optimization design on the broaching structure, so that the manufacturing cost is greatly reduced. The ABAQUS software has stronger nonlinear processing capability and can well simulate the large deformation of a workpiece material and the stress distribution of a cutter material in the broaching process. The DEFORM software has established a relatively perfect simulation interface in the fields of cutting, rolling and the like, but the overall calculation result is still in a gap with the test, and the DEFORM software is still a grid redrawing method in the cutting field. ADVANTAGE software has complete simulation analysis of machining methods such as cutting, milling and drilling. However, these commercial software can only simulate a single physical field (mainly a mechanical stress field), and cannot add the flow field of the coolant to the simulation, so that the cooling and lubricating effects of the coolant on the workpiece and the tool in the broaching process cannot be accurately simulated. Therefore, the simulation is developed by adopting the current single software platform, and the obtained simulation result has insufficient precision.
Disclosure of Invention
The invention provides a simulation analysis method for a mortise broaching process based on thermal-force-flow multi-field coupling, which aims to solve the technical problem that the precision of an obtained simulation result is insufficient because only a single physical field (mainly a mechanical stress field) can be simulated when a single software platform is adopted to carry out simulation at present and the cooling and lubricating actions of cooling liquid on a workpiece and a cutter in the broaching process cannot be accurately simulated.
The technical scheme adopted by the invention is as follows:
a mortise broaching process simulation analysis method based on thermal-force-flow multi-field coupling comprises the following steps:
establishing a broaching heat-force model according to the sizes of the cutter and the workpiece, the relevant parameters of the material, the relevant cutting parameters and the heat conduction characteristics and carrying out simulation;
establishing a broaching heat-flow model according to cooling related parameters of a cutter, a workpiece and cooling liquid and performing analog simulation;
and coupling the simulation results of the broaching heat-force model and the broaching heat-flow model to obtain a broaching heat-force-flow multi-field coupling model, and simulating the cooling effect of cooling liquid on a workpiece, a cutter and chips in the broaching process.
Further, the method for establishing the broaching heat-force model and performing simulation according to the sizes of the cutter and the workpiece, the relevant parameters of the material, the relevant parameters of cutting and the heat conduction characteristics specifically comprises the following steps:
establishing a tool broaching preliminary three-dimensional physical model;
determining the heat source and the transfer path of chips in the broaching process:
simplifying the geometric model, and correspondingly reducing the cutter model and the working area;
determining a workpiece and the size thereof, and defining the height of the workpiece to be more than 5 times of the cutting amount;
inputting material properties of a workpiece and a cutter;
determining cutter structure parameters, wherein the cutter structure parameters comprise a cutting edge obtuse circle radius, a tooth lift, a front angle and a back angle;
drawing a finite element mesh model;
setting the friction coefficient between the workpiece and the cutter;
inputting broaching parameters, and determining broaching speed, broaching length and initial temperature of a workpiece and a cutter according to actual operation conditions;
finite element iteration solution is carried out: and determining the distance of the tool advancing per second as a step length based on the broaching speed, calculating the broaching deformation, deformation heat, deformation stress and heat transfer of each step, distributing the parameters on each grid, setting each node to reach a balance state as a convergence basis, and repeating the iteration to converge the whole grid model to obtain a simulation calculation result.
Further, the establishing of the tool broaching preliminary three-dimensional physical model specifically comprises the following steps:
according to the width size of the mortise and the thickness size of the wheel disc, the preliminary tooth space is designed according to the principle that 2-5 teeth are distributed in the thickness direction of a single wheel disc, a certain tooth lift is designed according to the preliminary scheme of the total broaching amount and the tooth number between teeth, and a preliminary three-dimensional physical model with a front cutter angle of 85-90 degrees and a rear cutter angle of 0-10 degrees is established.
Furthermore, when a chip heat source and a chip heat transfer path in the broaching process are determined, the plastic deformation heat of a shearing surface, the frictional heat of a cutter front tool face and chips and the frictional heat of a cutter rear tool face and a workpiece in the metal broaching process are set as three main heat sources, and the generated heat is determined by the product of the broaching force, the broaching travel amount and the broaching speed; the heat generated by the cutting is transferred to the chips, the workpiece and the tool, respectively, while the heat transferred to the surrounding medium is minimal.
Further, the material properties of the workpiece and the cutter comprise tensile strength, yield strength, hardness, material composition and breaking strain, and the stress-strain curve input is measured by using a material database card carried by commercial software or through experiments.
Further, the drawing of the finite element mesh model specifically includes the steps of:
according to the structural characteristics of the cutter, the length of the front cutter face and the length of the back cutter face of the cutter, the size of the maximum cutter unit grid, the size of the minimum unit grid and the grid gradient are drawn in the shapes of triangle, quadrangle and regular hexagon, and the geometric model is converted into a finite element model.
Further, the method for establishing the broaching heat-flow model according to the cooling related parameters of the cutter, the workpiece and the cooling liquid and performing simulation specifically comprises the following steps:
establishing a three-dimensional physical model of the cutter, the workpiece and the cooling liquid spray pipe;
and (3) meshing the cutter teeth, the wheel disc and the surrounding area of the cooling liquid spray pipe: encrypting the cutter teeth, the wheel disc and the surrounding area of the cooling liquid spray pipe by adopting a Poly-Hexcore division method;
setting properties of a fluid material, including liquid water and air;
setting a boundary condition: setting the inlet of the upper and lower spray pipes as speed inlet with value of 5m/s, setting the outlet as pressure outlet with standard atmospheric pressure, setting the outlet gauge pressure as 0;
solving and setting: selecting Pressure-Baesd type as Pressure-based solver, selecting a Transient model for simulating the flowing process of the cooling liquid, wherein the gravity acceleration is 9.8m/s2(ii) a The turbulence model selects an RNG k-epsilon model, and the multiphase flow model tracks the liquid level by using a VOF model.
Further, when three-dimensional physical models of the cutter, the workpiece and the cooling liquid spray pipe are established, 1/4 wheel discs and part of cutter teeth are taken to establish the models; two cooling liquid spray pipes are established, the diameter of a nozzle outlet of each cooling liquid spray pipe is 2mm, the cooling liquid spray pipes form an angle of 45 degrees with the horizontal direction, and cooling liquid is sprayed on the upper surface and the lower surface of the broach respectively.
Further, the step of coupling the simulation results of the broaching heat-force model and the broaching heat-flow model to obtain a broaching heat-force-flow multi-field coupling model, and simulating the cooling effect of the cooling liquid on the workpiece, the tool and the chips in the broaching process, specifically comprises the steps of:
loading a broaching heat-force model and a broaching heat-flow model;
specifying the surfaces to be coupled in the broaching heat-force model and the broaching heat-flow model;
setting coupling parameters and a time step delta t, wherein the coupling parameters comprise: in broaching heat-force simulation, deformation analysis gives node velocity
By
Calculating to obtain strain rate and strain, and simultaneously carrying out thermal analysis on the workpiece and the cutter to obtain the temperature distribution T of the surfaces of the workpiece and the cutterB(ii) a In the broaching heat-flow simulation, the flow of the cooling liquid is analyzed, and the surface temperature T of the workpiece and the cutter under the action of the cooling liquid is obtainedD；
And repeatedly and alternately carrying out iterative solution by adopting deformation analysis and thermal analysis according to the coupling parameters and the time step delta t until the two solutions are converged.
Further, the iterative solution is repeatedly and alternately performed by adopting deformation analysis and thermal analysis according to the coupling parameter and the time step Δ t until both solutions converge, and the method specifically comprises the following steps:
(1) according to node speed
Updating the finite element mesh of the model with the time step delta t and giving ti+1The grid configuration at the moment, and the equivalent strain of the new configuration is calculated
(2) Will tiThe convergence solution of the node velocity and temperature at the moment is the (i + 1) th timeInitial guess of pace, namely:
in the formula, i represents the iteration sequence number of the deformation and thermal analysis iteration loop;
(3) and (3) iterating and circulating until convergence:
according to
Performing deformation analysis of the workpiece and the tool, and converging the result
According to
And
performing thermal analysis of the workpiece and the tool, the results converging to
According to
Thermal analysis of the workpiece/tool and coolant is performed with the results converging to
According to convergence, look at
And
whether or not to respectively and
and
if the difference exceeds the threshold, the convergence is not satisfactory, the serial number j of the iteration loop is added by 1, and the step (3) is repeated to continue the iteration loop; if the convergence is satisfactory, the step number i +1 is returned to the step (1).
The invention has the following beneficial effects:
according to the mortise broaching process simulation analysis method based on the thermal-force-flow multi-field coupling, the broaching simulation process is simulated, thermal-force and thermal-flow simulation analysis models in the broaching process are established, a data transmission platform between the models is established, coupling simulation analysis between the broaching thermal-force-flow fields is realized, the flow speed, the temperature and the impact pressure of cooling liquid are fully considered, and the simulation precision is greatly improved. The heat-force-flow multi-field coupling model can reproduce the distribution rule of cooling liquid on the surfaces of the workpiece and the cutter, truly reflects the heat transfer process among the workpiece, the cutter and the cooling liquid, and can also accurately output the temperature distribution, the stress strain distribution, the chip forming shape and the broaching force change curve of the workpiece and the cutter in the broaching process, thereby effectively guiding the design of structural parameters of the broaching tool.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic flow chart of a simulation analysis method of a thermal-force-flow multi-field coupling based mortise broaching process according to a preferred embodiment of the invention.
Fig. 2 is a flow chart illustrating the sub-steps of step S1 according to another preferred embodiment of the present invention.
Fig. 3 is an equivalent schematic view of a broach and mortise broaching according to a preferred embodiment of the present invention.
Fig. 4 is a schematic diagram of a broaching tool and a workpiece grid model in accordance with a preferred embodiment of the present invention.
Fig. 5 is a flow chart illustrating the sub-steps of step S2 according to another preferred embodiment of the present invention.
Fig. 6 is a flow chart illustrating the sub-steps of step S3 according to another preferred embodiment of the present invention.
FIG. 7 is a schematic diagram of grid association and data mapping between boundaries.
Fig. 8 is a flow chart illustrating the sub-steps of step S34 according to another preferred embodiment of the present invention.
Fig. 9(a) is a temperature distribution cloud during model broaching without taking cooling of the coolant into consideration.
Fig. 9(b) is a temperature distribution cloud in a model broaching process in consideration of cooling of the coolant.
Fig. 10(a) is a stress distribution cloud during model broaching without taking cooling of the coolant into consideration.
Fig. 10(b) is a stress distribution cloud in a model broaching process in consideration of cooling of the coolant.
FIG. 11 is a graph illustrating a comparison of the X, Y directional broaching force curves during broaching in different models.
Fig. 12 is a schematic view of the entire structure of the broach according to embodiment 1.
Fig. 13 is a partially enlarged view of the broach according to example 1.
Fig. 14 is a graph comparing the effect of tool rake angle on cutting temperature.
Fig. 15 is a graph of X, Y directional cutting force component as a function of rake angle and time.
Fig. 16 is a schematic view of the entire structure of the broach according to embodiment 2.
Fig. 17 is a partially enlarged view of the broach according to example 2.
FIG. 18 is a graph comparing the effect of different rounding radii on cutting stress.
Figure 19 is a graphical representation of X, Y directional cutting force as a function of edge rounding radius and time.
Fig. 20 is a schematic view of the entire structure of the broach according to embodiment 3.
Fig. 21 is a partially enlarged view of the broach according to example 3.
Fig. 22 is a comparison result of simulation of the influence of different tooth lift amounts on the residual stress (X direction).
Fig. 23 is a graphical representation of the X, Y directional cutting force as a function of tooth lift and time.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
Referring to fig. 1, a preferred embodiment of the present invention provides a simulation analysis method for a mortise broaching process based on thermal-force-flow multi-field coupling, comprising the steps of:
s1, establishing a broaching heat-force model according to the sizes of the cutter and the workpiece, the relevant parameters of the material, the relevant parameters of cutting and the heat conduction characteristics, and performing simulation;
s2, establishing a broaching heat-flow model according to cooling related parameters of the cutter, the workpiece and the cooling liquid and performing simulation;
and S3, coupling the simulation results of the broaching heat-force model and the broaching heat-flow model to obtain a broaching heat-force-flow multi-field coupling model, and simulating the cooling effect of cooling liquid on the workpiece, the cutter and the cutting chips in the broaching process.
According to the mortise broaching process simulation analysis method based on the thermal-force-flow multi-field coupling, the broaching simulation process is simulated, thermal-force and thermal-flow simulation analysis models in the broaching process are established, a data transmission platform between the models is established, coupling simulation analysis between the broaching thermal-force-flow fields is achieved, the flow speed, the temperature and the impact pressure of cooling liquid are fully considered, and the simulation precision is greatly improved. The heat-force-flow multi-field coupling model can reproduce the distribution rule of cooling liquid on the surfaces of the workpiece and the cutter, truly reflects the heat transfer process among the workpiece, the cutter and the cooling liquid, and can also accurately output the temperature distribution, the stress strain distribution, the chip forming shape and the broaching force change curve of the workpiece and the cutter in the broaching process, thereby effectively guiding the design of structural parameters of the broaching tool.
As shown in fig. 2, in the preferred embodiment of the present invention, the establishing of the broaching heat-force model and the simulation based on the dimensions of the tool and the workpiece, the material-related parameters, the cutting-related parameters and the heat conduction characteristics specifically include the steps of:
s11, establishing a tool broaching preliminary three-dimensional physical model;
according to the width size of the mortise and the thickness size of the wheel disc, the preliminary tooth space is designed according to the principle that 2-5 teeth are distributed in the thickness direction of a single wheel disc, and a certain tooth lifting amount (generally 10) is designed according to the preliminary scheme of the total broaching amount and the tooth number between teeth- 2mm), establishing a preliminary three-dimensional model with a front knife angle of approximately 90 degrees and a rear knife angle of 0-10 degrees, as shown in figure 3;
s12, determining a chip heat source and a chip heat transfer path in the broaching process;
in the metal broaching process, plastic deformation heat of a shearing surface, frictional heat of a front cutter face and chips of a cutter and frictional heat of a rear cutter face and a workpiece are three main heat sources, and about 98% of energy consumed in cutting is converted into heat energy. The amount of heat Q generated per unit time during cutting is equal to the work W performed per unit time in the primary motion. Therefore, the generated heat amount is determined by the product of the broaching force, the broaching advance amount, and the broaching speed.
The heat generated by the cutting is transferred to the chips, the workpiece and the tool, respectively, while the heat transferred to the surrounding medium is minimal. The percentage of heat transferred between them varies with the workpiece material, the amount of cut, the tool material, and the tool geometry. The greater the thermal conductivity K of the workpiece material, the more heat is transferred from the workpiece; the higher the cutting speed, the more heat is removed by the chip and the less heat is transferred from the workpiece and the tool, because the heat transfer time from the chip to the workpiece and the tool decreases as the cutting speed increases. The heat transfer equation for a planar orthogonal cut can be expressed as:
in the formula: q ═ qp+qfTotal heat production rate per unit volume; ρ is the density of the workpiece material (kg/m)3) (ii) a k is the heat transfer coefficient of the workpiece material; c. CpIs the specific heat (J/Kg. DEG C) of the workpiece; x and y are cartesian coordinate systems. u and v are the x and y directional components of the moving heat source.
Cutting heat due to plastic deformation:
wherein q ispVolumetric heat flow rate, η, generated for plastic deformation workpIs a plastic work conversion coefficient, generally takes a value of 0.9-0.95, here takes a value of 0.9,
respectively equivalent stress and equivalent strain, and J is a thermal equivalent coefficient.
Heat generated by rake face rubbing:
qf＝ηfτfrvchip/J
wherein q isfVolumetric heat flow rate, v, generated for frictional workchipIs the relative slip rate, ηfThe coefficient for the conversion of frictional work into heat is typically 0.5, i.e. it is assumed that half of the frictional heat is transferred to the chip and the tool, respectively.
S13, simplifying the geometric model, and correspondingly reducing the cutter model and the working area;
to reduce the finite element simulation computation time, the geometric model needs to be simplified. Because the tooth lifting amount of broaching is small, in order to divide meshes, optimize a cutting process and shorten the time required by simulation, when the broaching process is simulated, a cutter model and a working area are correspondingly reduced, and the broaching machine is calculated according to the following formula:
Pz＝pzbzkykδ
in the formula: pzBroaching force (N), b-broaching width (mm), z-number of teeth simultaneously participating in broaching, kyCorrelation correction taking into account the change in the rake angle of the toolParameter, kδ-taking into account relevant correction parameters of wear of the cutting teeth of the broach.
From the above formula, the broaching force is proportional to the broaching width, so that the broaching width of the broach is reduced to several millimeters when calculating the influence of relevant parameters on cutting. When analyzing the influence of the broaching parameters on broaching, the cutter is simplified into a single-tooth model. And then setting the workpiece material to be rigid and not to move, and uniformly broaching the workpiece material from one side to the other side by the cutter. During broaching, the movement of the workpiece and the tool is relatively constant, and the broaching speed of the tool is correspondingly simulated in a boundary condition mode according to the parameter input of the actual machining process.
S14, determining the workpiece and the size thereof, and defining the height of the workpiece to be more than 5 times of the cutting amount;
the workpiece size is the working size of the simulation model. In order to obtain reasonable simulation results and minimize the boundary effect generated by the workpiece, the height of the workpiece is generally defined to be more than 5 times of the cutting amount.
S15, inputting material properties of the workpiece and the cutter;
the heat of deformation is calculated in the process of broaching and material removing, and mechanical performance indexes of the workpiece and the cutter material, such as tensile strength, yield strength, hardness, material components, fracture strain and the like, need to be used. There are 2 ways to obtain: 1) a material database card carried by commercial software is adopted; 2) the stress-strain curve input was measured experimentally.
S16, determining cutter structure parameters, wherein the cutter structure parameters comprise a cutting edge obtuse circle radius, a tooth lift, a front angle and a rear angle;
every time one round of simulation is executed, parameters such as the obtuse circle radius of the cutting edge of the cutter, the tooth lifting amount, the front angle and the back angle need to be input. These parameters are also parameters that need to be adjusted and changed for each round of the optimal design. Common parameters are generally input from a conventional structural scheme, and then optimization is performed according to a simulation result.
S17, drawing a finite element mesh model;
according to the structural characteristics of the cutter, the length of the front cutter face and the length of the back cutter face of the cutter, the size of the maximum cutter unit grid, the size of the minimum unit grid and the grid gradient are drawn in the shapes of triangle, quadrangle, regular hexagon and the like, and the geometric model is converted into a finite element model. It is generally necessary to set the cutting edge and the workpiece surface to a mesh size smaller in size, as shown in fig. 4.
S18, setting the friction coefficient between the workpiece and the cutter;
the friction factor between the workpiece and the tool has a significant influence on the simulation result, and a Coulomb friction model is generally adopted in common commercial software:
Ff≤μFn
in the formula FnIs the normal force applied by the surface, mu is the friction factor, FfIs the corresponding friction.
S19, inputting broaching parameters, and determining broaching speed, broaching length and initial temperature of the workpiece and the cutter according to actual operation conditions;
s20, finite element iteration solution is carried out;
and determining the distance of the tool advancing per second as a step length based on the broaching speed, calculating the broaching deformation, deformation heat, deformation stress and heat transfer of each step, distributing the parameters on each grid, setting each node to reach a balance state as a convergence basis, and repeating the iteration to converge the whole grid model to obtain a simulation calculation result.
As shown in fig. 5, in the preferred embodiment of the present invention, the establishing a broaching heat-flow model according to cooling related parameters of the tool, the workpiece and the cooling fluid and performing simulation specifically includes the steps of:
s21, establishing a three-dimensional physical model of the cutter, the workpiece and the cooling liquid spray pipe;
when a three-dimensional physical model of a cutter, a workpiece and a cooling liquid spray pipe is established, in order to avoid unnecessary calculation time and ensure normal solution of the model, 1/4 wheel discs and partial cutter teeth are taken to establish the model; establishing two cooling liquid spray pipes, wherein the diameter of a nozzle outlet of each cooling liquid spray pipe is 2mm, the angle between each cooling liquid spray pipe and the horizontal direction is 45 degrees, and cooling liquid is sprayed on the upper surface and the lower surface of the broach respectively;
s22, meshing the cutter teeth, the wheel disc and the surrounding area of the cooling liquid spray pipe;
the method for dividing the cutter teeth, the wheel disc and the spray pipe by adopting the Poly-Hexcore (polyhedron + hexahedral core grid) is adopted to encrypt the areas around the cutter teeth, the wheel disc and the spray pipe, so that the interface of cooling liquid and air is better captured, and the precision is improved;
s23, setting the properties of the fluid material, including liquid water and air;
s24, setting boundary conditions: setting the inlet of the upper and lower spray pipes as speed inlet with value of 5m/s, setting the outlet as pressure outlet with standard atmospheric pressure, setting the outlet gauge pressure as 0;
s25, solving and setting: selecting Pressure-Baesd type as Pressure-based solver, selecting a Transient model for simulating the flowing process of the cooling liquid, wherein the gravity acceleration is 9.8m/s2(ii) a The turbulence model selects an RNG k-epsilon model, and the multiphase flow model tracks the liquid level by using a VOF model.
As shown in fig. 6, in a preferred embodiment of the present invention, the step of coupling the simulation results of the broaching heat-force model and the broaching heat-flow model to obtain a broaching heat-force-flow multi-field coupling model, and simulating the cooling effect of the cooling liquid on the workpiece, the tool, and the chips during the broaching process, specifically includes the steps of:
s31, loading a broaching heat-force model and a broaching heat-flow model;
s32, specifying the surfaces needing to be coupled in the broaching heat-force model and the broaching heat-flow model;
s33, setting coupling parameters and a time step delta t, wherein the coupling parameters comprise: in broaching heat-force simulation, deformation analysis gives node velocity
By
Calculating to obtain strain rate and strain, and simultaneously carrying out thermal analysis on the workpiece and the cutter to obtain the temperature distribution T of the surfaces of the workpiece and the cutterB(ii) a In the broaching heat-flow simulation, the flow of the cooling liquid is analyzed, and the cooling liquid is obtainedSurface temperature T of workpiece and tool under actionD；
And S34, repeatedly and alternately carrying out iterative solution by adopting deformation analysis and thermal analysis according to the coupling parameters and the time step delta t until the two solutions are converged.
In this embodiment, the coupling of the deformation analysis and the thermal analysis of the broaching workpiece is realized through the constitutive relation of the material, the thermal analysis in the broaching process mainly consists of three parts, namely, the thermal analysis of the workpiece, the thermal analysis of the tool, and the thermal analysis of the workpiece, the tool, and the cooling liquid, the thermal analysis of the workpiece, the tool, and the cooling liquid performs grid association mapping by applying boundary conditions, as shown in fig. 7, specifically, a unified coordinate system is constructed by using McPPI software, a coupling surface is automatically identified, whether grids are matched or not is judged by using a highly efficient barrel-type pre-contact search algorithm, and the association mapping between grids is realized based on a common point mapping algorithm and grid matching and interpolation of adjacent closest points.
The thermal-force-flow coupling during broaching is repeated and alternated with deformation analysis and thermal analysis until both solutions converge. In thermal-force simulation, deformation analysis gives the velocity of the node
The strain rate and the strain can be calculated, and the temperature distribution T of the surfaces of the workpiece and the cutter can be obtained by carrying out thermal analysis on the workpiece and the cutterB. In the heat-flow simulation, the flow of the cooling liquid is analyzed to obtain the surface temperature T of the workpiece and the cutter under the action of the cooling liquidD. Suppose that at a certain time tiThe above-mentioned total field vector
TB、TDA converged solution is obtained (subscript i indicates time series), and t is found nexti+1Time (t)i+1＝ti+ Δ t) convergent solution for node velocity and temperature.
As shown in fig. 8, in a preferred embodiment of the present invention, the iteratively solving by repeatedly and alternately performing deformation analysis and thermal analysis according to the coupling parameter and the time step Δ t until both solutions converge specifically includes the steps of:
s341, according to the node speed
Updating the finite element mesh of the model with the time step delta t and giving ti+1The grid configuration at the moment, and the equivalent strain of the new configuration is calculated
S342, mixing tiThe converged solution of node velocity and temperature at time instant is taken as the initial guess at the i +1 time step, i.e.:
in the formula, i represents the iteration sequence number of the deformation and thermal analysis iteration loop;
and S343, iterating and circulating until convergence:
according to
Performing deformation analysis of the workpiece and the tool, and converging the result
According to
And
performing thermal analysis of the workpiece and the tool, the results converging to
According to
Thermal analysis of the workpiece/tool and coolant is performed with the results converging to
According to convergence, look at
And
whether or not to respectively and
and
if the difference exceeds the threshold, the convergence is not satisfactory, the iteration cycle number j is added by 1, and the step S343 is repeated to continue the iteration cycle; if the convergence is satisfactory, the step number i +1 returns to step S341.
Comparing the results of the thermal-force-flow multi-field coupling simulation with the traditional broaching simulation:
the heat-force-flow multi-field coupling model can accurately simulate the cooling effect of cooling liquid on workpieces, cutters and chips in the broaching process, and compared with the simulation method in the prior art, the method has higher accuracy.
By adopting the simulation analysis method, the effects of a plurality of physical fields such as force, temperature and the like can be considered at the same time, the obtained result is more accurate than the result obtained by the prior art, and as can be seen from fig. 9(a) and 9(b), if the traditional method is adopted for modeling simulation, the obtained cutting temperature gradient distribution is smaller and is not accurate enough. By adopting the simulation analysis method, the temperature distribution under the action of the cooling liquid can be more definitely obtained: the coolant has no effect on the maximum temperature of the tip, but has a significant effect on the temperature distribution of the workpiece and tool around the tip. The high temperature calculated by adopting the multi-field coupling model is only concentrated at the tool nose, and the cooling speed to the periphery is higher than that of the traditional model.
FIGS. 10(a) and 10(b) are stress distribution clouds obtained from conventional methods without consideration of cooling and the simulation analysis method of the present invention. The maximum stress difference calculated by the two models is smaller, but the large stress coverage area of the tool nose calculated by the multi-field coupling model is smaller than that of the traditional model, the shear stress of the chip root is smaller than that of the traditional model, the stress distribution of the tool nose can be more accurately reflected, and the method is more effective for predicting the forming simulation of cutting.
Fig. 11 is a graph showing a comparison of the curves of the broaching force of the tool parallel to the broaching direction (X direction) and perpendicular to the broaching direction (Y) in the broaching process, obtained by the conventional method and the present invention. The broaching force calculated by the multi-field coupling simulation model can reflect the fluctuation of the broaching force more accurately, particularly the X direction is obvious, and the method is very important for evaluating the service life of the cutter in the broaching process.
The invention can observe the distribution rules of stress, strain, temperature, broaching force and the like of the cutter and the mortise part from the simulation iteration output result, judge whether the numerical values are in a safe range or not, so as to confirm whether the structural parameters of the used cutter are reasonable or not, and generally take the small broaching force, the low temperature distribution of the cutting edge, the reasonable scrap curl and the like as the criteria. And by comparing simulation results of different broach structure parameters, broaching working conditions are obtained so as to obtain more reasonable broach structures or broaching process parameters. Through repeated and repeated broaching simulation for multiple times and structural parameter improvement of the cutter, the structural parameter of the cutter can be quickly optimized, so that the manufacturing and testing processes of the cutter with high cost and long period are avoided.
Example 1: simulation optimization of broach rake angle
The broach material is M42 quenched and tempered high-speed steel, the mortise wheel disc is GH4169 aged nickel-based high-temperature alloy material, and the broach adopted by broaching has a three-dimensional structure as shown in figures 12 and 13. The parameters of the cutter are as follows: the back angle is 3 degrees, the radius of the blunt circle of the cutting edge is 0.02mm, the tooth lift is 0.03mm, the broaching speed is 6m/min, and the influence of the size of the front angle on the broaching simulation temperature distribution is contrastively analyzed. Broaching simulations were performed for tools with rake angles of 6 °, 10 °, 15 °, and 18 °, respectively.
The simulation and tool parameter optimization steps of this embodiment are repeated to obtain the simulation results of the edge temperature distribution rule and the broaching force when different rake angle parameters are obtained, as shown in fig. 14. From the simulation results, it can be seen that when the rake angle is 18 °, the temperature of the cutting region is the lowest, and the heat affected zone of the tip and the machined surface is small. When the cutting temperature is high at a rake angle of 6 °, the heat affected zone is large. Therefore, it can be seen that increasing the rake angle is advantageous for reducing the cutting temperature.
The temperature distribution of the cutter is not obviously changed along with the increase of the rake angle of the cutter, but the temperature of the cutter tip is gradually reduced, because the rake angle is increased, the deformation of chips is reduced, the cutting power is reduced, and the heat generated during cutting is reduced; the highest temperature is concentrated on the rake face near the nose area. Further, the distribution law of the broaching force when the tool with different rake angles is broached is analyzed and compared, as shown in fig. 15, graphs of the change of the cutting component force along the rake angle and the time in the X direction and the Y direction are respectively listed.
As the rake angle increases from 6 ° to 18 °, the maximum tip temperature gradually decreases, the stress range gradually decreases, and the broaching forces both X and Y gradually decrease. The reason is that the cutting edge becomes smaller as the number of the rake angle increases, the metal material is easier to be cut off by the tool, the contact area of the rake face and the chips is reduced, and the friction is reduced, so that the work of the broach is reduced, the main broaching force is reduced, the cutting temperature is reduced, and the rake angle is increased to facilitate cutting. However, excessive rake angles can result in reduced tool strength. The simulation analysis result is comprehensively considered, and the front angle of 10-15 degrees can be reasonably selected.
Example 2: simulation optimization of blunt circular radius of broach edge
The broach material is ASP2015 powder metallurgy steel quenching and tempering state material, the mortise wheel disc is FGH95 aging state nickel-based high-temperature alloy material, and the broach adopted by broaching has a three-dimensional structure as shown in figures 16 and 17. The parameters of the cutter are as follows: the front angle and the back angle are respectively 10 degrees and 3 degrees, the broaching speed is 2m/min, the tooth lifting amount is 0.03mm, the broaching speed is 6m/min, and the influence of the size of the blunt radius of the blade on the broaching simulation temperature distribution is contrastively analyzed. Broaching simulation of cutters with blunt radiuses of the blades of 0.01mm, 0.02mm, 0.03mm and 0.04mm is carried out.
FIG. 18 is a graph comparing the effect of various edge rounding radii on cutting Stress (Misses Stress). From the results, it is understood that the stress decreases as the radius of the blunt circle increases. When the radius of the blunt circle is smaller, the stress is concentrated at the transition part of the blunt circle and the rear cutter surface, the stress value is reduced along with the increase of the radius of the blunt circle, the stress action range is diffused, and the stress annularly surrounds the circumference of the blunt circle.
FIG. 19 is a graph showing X, Y directional cutting force as a function of blunt edge radius and time, with the blunt edge radii from bottom to top being 0.01mm, 0.02mm, 0.03mm and 0.04mm, respectively. From the results, it can be seen that: the cutting force is increased along with the increase of the blunt radius of the cutting edge of the cutter, and the cutting force is also obviously increased along with the increase of the blunt radius, so that the extrusion effect and the cutting effect of the cutter on the surface of a workpiece are both increased along with the increase of the blunt radius, and the extrusion effect in the Y direction is obvious, so that the obvious change of the cutting force in the Y direction is caused. Therefore, reducing the tool's obtuse radius is beneficial to reducing the cutting force, if conditions permit.
The structure of the comprehensive consideration simulation analysis is because along with the increase of blade blunt circle, temperature rise is obvious, but the stress value reduces, and the stress effect scope spreads, and the cutting force increases along with cutter blade blunt circle radius increase, consequently suitably reduces blade blunt circle and can reduce temperature and cutting force, but can lead to stress concentration, can design 0.02 ~ 0.03mm for better scope.
Example 3: simulation optimization of broach tooth lift
The broach material is M42 high-speed steel quenching and tempering state material, the mortise wheel disc is FGH95 aging state nickel-based high-temperature alloy material, and the broach adopted by broaching has a three-dimensional structure as shown in figures 20 and 21. The rake angle and the relief angle of the broach were 10 ° and 3 °, respectively, and the broaching speed was 2 m/min. Broaching simulation of cutters with tooth lifting amounts of 0.02mm, 0.03mm, 0.04mm and 0.05mm is carried out.
Fig. 22 is a simulation comparison result of the influence of different tooth lift amounts on the residual stress (X direction). As can be seen from the figure, the residual stress distribution area gradually increases as the tooth lifting amount increases.
FIG. 23 is a diagram illustrating the variation of the cutting force in the direction X, Y with the tooth lifting amount of the tool and the time, which is a variation curve of the broaching force with the tooth lifting amount of 0.02mm, 0.03mm, 0.04mm and 0.05mm from bottom to top. The cutting force in the X direction is obviously increased along with the increase of the tooth lifting amount, and the cutting force in the Y direction is also increased along with the increase of the tooth lifting amount, so that the pressing effect of the cutter on the surface of a workpiece is gradually increased along with the increase of the tooth lifting amount. Therefore, reducing the tooth lift is advantageous for reducing the cutting force.
The comprehensive simulation analysis structure increases the cutting edge temperature and the participation stress of the workpiece along with the increase of the tooth lifting amount. However, in view of the change of the broaching force with time, when the tooth lift is 0.03mm, the broaching force is more stable with time, which is advantageous for increasing the life of the broach. Therefore, the tooth lifting amount can be designed to be about 0.03mm reasonably.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A mortise broaching process simulation analysis method based on thermal-force-flow multi-field coupling is characterized by comprising the following steps:
establishing a broaching heat-force model according to the sizes of the cutter and the workpiece, the relevant parameters of the material, the relevant cutting parameters and the heat conduction characteristics and carrying out simulation;
establishing a broaching heat-flow model according to cooling related parameters of a cutter, a workpiece and cooling liquid and performing analog simulation;
and coupling the simulation results of the broaching heat-force model and the broaching heat-flow model to obtain a broaching heat-force-flow multi-field coupling model, and simulating the cooling effect of cooling liquid on a workpiece, a cutter and chips in the broaching process.
2. The method for simulating and analyzing the mortise broaching process based on the heat-force-flow multi-field coupling according to claim 1, wherein the method for simulating and establishing the broaching heat-force model according to the sizes of the tool and the workpiece, the relevant parameters of the material, the relevant parameters of cutting and the heat conduction characteristics comprises the following steps:
establishing a tool broaching preliminary three-dimensional physical model;
determining the heat source and the transfer path of chips in the broaching process:
simplifying the geometric model, and correspondingly reducing the cutter model and the working area;
determining a workpiece and the size thereof, and defining the height of the workpiece to be more than 5 times of the cutting amount;
inputting material properties of a workpiece and a cutter;
determining cutter structure parameters, wherein the cutter structure parameters comprise a cutting edge obtuse circle radius, a tooth lift, a front angle and a back angle;
drawing a finite element mesh model;
setting the friction coefficient between the workpiece and the cutter;
inputting broaching parameters, and determining broaching speed, broaching length and initial temperature of a workpiece and a cutter according to actual operation conditions;
finite element iteration solution is carried out: and determining the distance of the tool advancing per second as a step length based on the broaching speed, calculating the broaching deformation, deformation heat, deformation stress and heat transfer of each step, distributing the parameters on each grid, setting each node to reach a balance state as a convergence basis, and repeating the iteration to converge the whole grid model to obtain a simulation calculation result.
3. The simulation analysis method for the mortise broaching process based on the thermal-force-flow multi-field coupling as claimed in claim 2, wherein the establishing of the preliminary three-dimensional physical model of the broaching tool specifically comprises the steps of:
according to the width size of the mortise and the thickness size of the wheel disc, the preliminary tooth space is designed according to the principle that 2-5 teeth are distributed in the thickness direction of a single wheel disc, a certain tooth lift is designed according to the preliminary scheme of the total broaching amount and the tooth number between teeth, and a preliminary three-dimensional physical model with a front cutter angle of 85-90 degrees and a rear cutter angle of 0-10 degrees is established.
4. The simulation analysis method for the mortise broaching process based on the heat-force-flow multi-field coupling as claimed in claim 2, wherein when determining the heat source and the transfer path of the chips in the broaching process, the plastic deformation heat of the shearing surface, the frictional heat of the tool rake face and the chips and the frictional heat of the tool flank face and the workpiece in the metal broaching process are set as three main heat sources, and the generated heat is determined by the product of the broaching force, the broaching travel amount and the broaching speed; the heat generated by the cutting is transferred to the chips, the workpiece and the tool, respectively, while the heat transferred to the surrounding medium is minimal.
5. The method for simulating and analyzing the mortise broaching process based on the thermal-force-flow multi-field coupling as claimed in claim 2, wherein the material properties of the workpiece and the tool include tensile strength, yield strength, hardness, material composition and fracture strain, and the stress-strain curve is input by using a material database card carried by commercial software or through experiments.
6. The method for simulating and analyzing the mortise broaching process based on the thermal-force-flow multi-field coupling as claimed in claim 2, wherein the step of drawing the finite element mesh model specifically comprises the steps of:
according to the structural characteristics of the cutter, the length of the front cutter face and the length of the back cutter face of the cutter, the size of the maximum cutter unit grid, the size of the minimum unit grid and the grid gradient are drawn in the shapes of triangle, quadrangle and regular hexagon, and the geometric model is converted into a finite element model.
7. The method for simulating and analyzing the mortise broaching process based on the thermal-force-flow multi-field coupling according to claim 1, wherein the broaching thermal-flow model is established according to cooling related parameters of a cutter, a workpiece and cooling liquid and simulation is carried out, and the method specifically comprises the following steps:
establishing a three-dimensional physical model of the cutter, the workpiece and the cooling liquid spray pipe;
and (3) meshing the cutter teeth, the wheel disc and the surrounding area of the cooling liquid spray pipe: encrypting the cutter teeth, the wheel disc and the surrounding area of the cooling liquid spray pipe by adopting a Poly-Hexcore division method;
setting properties of a fluid material, including liquid water and air;
setting a boundary condition: setting the inlet of the upper and lower spray pipes as speed inlet with value of 5m/s, setting the outlet as pressure outlet with standard atmospheric pressure, setting the outlet gauge pressure as 0;
solving and setting: selecting Pressure-Baesd type as Pressure-based solver, selecting a Transient model for simulating the flowing process of the cooling liquid, wherein the gravity acceleration is 9.8m/s2(ii) a The turbulence model selects an RNG k-epsilon model, and the multiphase flow model tracks the liquid level by using a VOF model.
8. The simulation analysis method for the mortise broaching process based on the thermal-force-flow multi-field coupling of claim 7, wherein 1/4 wheel discs and parts of cutter teeth are taken to establish a model when establishing a three-dimensional physical model of a cutter, a workpiece and a cooling liquid spray pipe; two cooling liquid spray pipes are established, the diameter of a nozzle outlet of each cooling liquid spray pipe is 2mm, the cooling liquid spray pipes form an angle of 45 degrees with the horizontal direction, and cooling liquid is sprayed on the upper surface and the lower surface of the broach respectively.
9. The method for simulating and analyzing the mortise broaching process based on the thermal-force-flow multi-field coupling as claimed in claim 1, wherein the broaching thermal-force model and the broaching thermal-flow model are coupled to obtain a broaching thermal-force-flow multi-field coupling model, and the cooling effect of the cooling liquid on the workpiece, the tool and the chips in the broaching process is simulated, and the method comprises the following steps:
loading a broaching heat-force model and a broaching heat-flow model;
specifying the surfaces to be coupled in the broaching heat-force model and the broaching heat-flow model;
setting coupling parameters and a time step delta t, wherein the coupling parameters comprise: in broaching heat-force simulation, deformation analysis gives node velocity
By
Calculating to obtain strain rate and strain, and simultaneously carrying out thermal analysis on the workpiece and the cutter to obtain the temperature distribution T of the surfaces of the workpiece and the cutterB(ii) a In the broaching heat-flow simulation, the flow of the cooling liquid is analyzed, and the surface temperature T of the workpiece and the cutter under the action of the cooling liquid is obtainedD；
And repeatedly and alternately carrying out iterative solution by adopting deformation analysis and thermal analysis according to the coupling parameters and the time step delta t until the two solutions are converged.
10. The method for simulating and analyzing the mortise broaching process based on the thermal-force-flow multi-field coupling according to claim 9, wherein the iterative solution is repeatedly and alternately performed by using deformation analysis and thermal analysis according to the coupling parameters and the time step Δ t until both solutions converge, and the method specifically comprises the following steps:
(1) according to node speed
Updating the finite element mesh of the model with the time step delta t and giving ti+1The grid configuration at the moment, and the equivalent strain of the new configuration is calculated
(2) Will tiThe converged solution of node velocity and temperature at time instant is taken as the initial guess at the i +1 time step, i.e.:
in the formula, i represents the iteration sequence number of the deformation and thermal analysis iteration loop;
(3) and (3) iterating and circulating until convergence:
according to
Performing deformation analysis of the workpiece and the tool, and converging the result
According to
And
performing thermal analysis of the workpiece and the tool, the results converging to
According to
Thermal analysis of the workpiece/tool and coolant is performed with the results converging to
According to convergence, look at
And
whether or not to respectively and
and
if the difference exceeds the threshold, the convergence is not satisfactory, the iteration cycle serial number j is added by 1, and the step (3) is repeated to continue the iteration cycle; such as convergenceAnd (4) if the performance is satisfactory, returning the time step number i +1 to the step (1).
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